Opportunities / Department of Energy

Technology licensing opportunity: scan-to-sample · Los Alamos, NM

Energy

TECHNOLOGY LICENSING OPPORTUNITY: Scan-to-Sample

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Description (excerpt)

Imagine loading an irregular block of metal, or a finished curved part, into a single station and walking away with precisely cut samples, no specialized machining expertise required. Scan-to-Sample from Los Alamos National Laboratory makes that possible by weaving 3D scanning, design software and computer-guided cutting into one continuous digital thread, running from the first scan straight through to the finished part. The system captures the true shape of the starting material, however curved or complex, then plans and carries out the cuts on its own, sparing operators the slow, error-prone job of hand-aligning and re-zeroing equipment for every specimen. The payoff is faster turnaround, less wasted material and consistent, repeatable quality, bringing advanced machining within reach of a far wider range of users and parts. How it Works The workflow begins when a scanning device, such as a laser scanner, optical scanner or contact probe, captures the exact geometry of the incoming material or part and produces an accurate digital 3D model. Design software then imports that model, where an operator marks the locations, orientations and sizes of the samples or features wanted, and the software calculates the tool paths needed to reach them. Those tool paths are converted into machine instructions, typically a G-code file, and loaded onto a computer numerical control machine, which secures the material and cuts the specimens by following the programmed paths without manual re-zeroing. After cutting, the finished part can be scanned again and compared against the original model to confirm that every specimen meets the required tolerances. Technical Description At its core, Scan-to-Sample links four cooperating elements: i) a scanning device that records the dimensional, geometric and surface characteristics of the workpiece; ii) an operations device that builds a watertight 3D model and generates the cutting program; iii) a machining apparatus such as a multi-axis CNC mill, turning center, grinder, laser or wire EDM system; and iv) a monitoring apparatus that verifies the outcome. The operations device applies a sample extraction model, which carries the functionality of standard CAD and CAM tools, to the 3D model so as to map sampling locations onto the true contours of the part and to derive the tool paths, cutting tools, spindle speeds, feed rates and fixturing choices suited to the material and its tolerances. Because the pipeline is driven by the scan …

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